Packaging insert

ABSTRACT

A collapsible insert for a carton for a product having a collapsible protruding member has a central panel with columnar channels formed at either end. The channels conform to the shape of the carton corners. The vertical columns have notched regions for receiving a product having a collapsible protruding member extending from the base thereof, such as a lawn mower deck and handle. The hollow columns provide spaces for articles to be packaged with the product. The central panel has a handhold opening to reinforce the carton handhold. The central panel&#39;s handhold opening is also reinforced.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] (Not applicable)

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT

[0002] (Not applicable)

TECHNICAL FIELD OF THE INVENTION

[0003] The present invention relates generally to a product carton, and, more particularly, to an insert for a carton for a product having collapsible protruding members.

BACKGROUND OF THE INVENTION

[0004] Individual products are often packaged for transport to and storage at a point of sale. An objective of the packaging process is to protect each item from damage during shipping. One means of protecting a product during shipping is to substantially immobilize the product so as to inhibit undesirable movement within the package that causes damage.

[0005] Some products have members that protrude a substantial distance outwardly of the base portion of the product. A walk-behind type lawn mower with a handle member that protrudes from the base lawn mower is an example of such a product. Products of this nature are particularly difficult to package because of the extended member. Such products can be more easily packaged and transported if the protruding member (such as the lawn mower handle) can be fully or partially collapsed into a less protruding condition or a condition lying substantially within the profile of the base portion of the product. Thus, it can be appreciated that it would be useful to have a means for packaging a product with a collapsible protruding member.

[0006] It is often desirable to ship a product with complementary articles such as parts or accessories. These articles must also be secured and protected during shipping. Thus, it can be further appreciated that it would be useful to have a means for protecting complementary articles shipped with products.

[0007] To optimize storage space for products, it is often desirable to store the products stacked vertically upon one another. However, a problem in stacking packages vertically is that the weight of an individual package or the combined weight of several stacked packages will cause the lowermost carton or cartons of packages to collapse. A collapsed carton typically results in damage to the product contained therein. Thus, it can be appreciated that it would be useful to have a means for reinforcing the stacking strength of cartons. If the thickness of carton walls is increased to increase vertical stacking strength, the bulkiness and cost of the carton may be unfavorably increased. Placing non-paperboard, reinforcing elements on or in the carton creates problems of adding to the weight of the package and/or reducing the amount of space available for packaging. Thus, it can be appreciated that it would be useful to have a means for reinforcing a carton that does not unfavorably increase the carton cost, thickness or weight and does not lessen the amount of space available for packing.

[0008] It can be greatly appreciated that it would be useful to have a means for optimally increasing the vertical stacking strength of a carton while also substantially immobilizing packaged products and complementary articles.

BRIEF SUMMARY OF THE INVENTION

[0009] The present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, according to one aspect of the present invention, a collapsible insert for a carton has a central panel interconnecting end portions. Tubular channel members are formed at the respective end portions of the central panel. A handhold opening is defined between the first and second end portions. When inserted into a carton, the handhold opening aligns with the handhold opening of the carton and reinforces the handhold.

[0010] Each channel member has a center channel panel, a first side panel foldably connected to the center channel panel and the central panel, and a second side panel foldably connected to the center channel panel and the central panel. Each channel member together with the central panel forms a hollow, collapsible vertical column. These vertical columns fill the corners of the carton to improve stacking strength while providing spaces for complementary articles in the carton. When the carton contains a partially assembled lawn mower, the hollow columns provide spaces for storing wheels as well as a cradle for the collapsed lawn mower handle. In addition, portions of the bottoms of the columns are removed to provide space for the lawn mower deck without weakening the insert.

[0011] The insert is formed from a single piece-blank that is glued and folded flat. When ready for use, the insert is quickly set up forming the columns and spaces for the lawn mower deck and loose components.

[0012] According to another aspect of the invention, a blank for a pop up support insert comprises first and second groups of panels mirroring one another about a vertical centerline. Each group of panels has a central panel with a downwardly projecting extension forming a leg for the support insert. A first side panel that has a downwardly projecting extension for the leg is foldably connected to the central panel. A center channel panel having top portion defining a notch and a bottom portion forming an extension for the leg is foldably connected to the first side panel opposite the central panel. A second side panel has a top portion defining a notch and is foldably connected to the center channel panel opposite the first side panel. A glue flap is foldably connected to the second side panel opposite the center channel panel.

[0013] The single piece blank provides notches for cradling the lawn mower handle and cutouts for handholds. Downwardly projecting extensions form legs supporting hollow storage columns and space for the deck of a lawn mower.

[0014] These and other aspects, objects, features and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiments and appended claims, and by reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0015]FIG. 1 is a perspective view of a preferred embodiment of an insert for a carton according to the present invention.

[0016]FIG. 2 is the insert of FIG. 1 in a substantially collapsed condition.

[0017]FIG. 3 is a blank for forming the insert of FIG. 1.

[0018]FIG. 4 illustrates the insert in use in a carton for a product having collapsible protruding elements.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0019] Referring to FIGS. 1-2, a collapsible insert 10 for a carton has a central panel 12 with left and right end portions and defines a reinforced handhold opening 14. A bottom portion of central panel 12 is removed except at the corners forming legs. Handhold opening 14 lies between the left and right end portions near the top of the central panel 12. Left and right channel members 16, 18 are respectively attached to the left and right end portions of the central panel. The channel members are identical and mirror one another across an imaginary vertical centerline 5 of the central panel.

[0020] The left channel member 16 has a center channel panel 20 with a top notch 22 extending from the top edge downward for receiving a portion of a lawn mower handle. A bottom portion of center channel panel 20 nearest the vertical centerline of central panel 12 is removed forming a notch for receiving a lawn mower deck. The remaining bottom portion of center channel panel 20 forms a leg 24 for supporting the insert.

[0021] A left side panel 26 is hingedly connected to both central panel 12 and center channel panel 20. The bottom portion of left side panel 26 forms part of support leg 24. Support leg 24 has two parallel members, center channel panel 20 and central panel 12, and a transverse member, left side panel 26. The three-sided leg adds vertical strength to the corners of a carton to allow vertical stacking.

[0022] A right side panel 28 is hingedly connected to both central panel 12 and center channel panel 20. The bottom edge of right side panel 28 is even with the notch of center channel panel 20 and resides above the deck of a lawn mower when in use. A top portion of right side panel 28 is removed forming a notch 30 for receiving a lawn mower handle. The U-shaped lawn mower handle makes its 90° transition between center channel panel notch 22 and right side panel notch 30.

[0023] The left channel member 16 is hingedly connected to central panel 12 and folds flat. When folded, left channel member 16 is displaced away from the vertical centerline of central panel 12 with center channel panel 20 overlaying left side panel 26. The right channel member is displaced to the right of the vertical centerline when folded flat. When erected, the channel members and central panel form two hollow columns suitable for holding instructional literature, wheels or other loose components.

[0024] Referring to FIG. 3, a single piece blank 32 for the insert is symmetrical about an imaginary vertical centerline 5 through central panel 12 with the left and right side mirroring one another. Central panel 12 has a cutout 34 to be removed to form handhold 14 in the erected insert. Panel 12 also has an extension 36 that forms part of the support leg 24 in the erected insert.

[0025] Left side panel 26 is foldably connected to central panel 12. Center channel panel 20 is foldably connected to left end panel 26. Along its top edge, there is a notch 22. Panel 20 has an extension 38 that forms part of the leg 24 in the erected insert. Right side panel 28 is foldably connected to center channel panel 20. Right side panel 28 has a notch at its top left corner. A glue flap 40 is foldably connected to right side panel 28. The insert is assembled from the blank by applying glue to glue flap 40. Center channel panel 20 is folded up and laid over left side panel 26 causing glue flap 40 to contact central panel 12 and adhere thereto. The same is done with the panels on the right of the centerline yielding a flat insert. The flat insert is erected by pushing in at the distal edges of the center channel panels.

[0026] Referring to FIG. 4, inserts 42, 44 are installed at opposite ends of a lawn mower carton 46. Insert 42 cradles the U-shaped portion of the lawn mower handle while insert 44 cradles the folded portion of the handle. Different mower widths can be accommodated by increasing the lateral dimension of the central panel. The lawn mower deck lies within the notches below the panels without actually touching the insert. The inserts fill the corners of the carton increasing the stacking strength. The inserts have hollow vertical columns that provide storage areas in the carton for product literature, a container of lubricant or detached wheels. Hardware or other complementary articles that are sold with the mower can be stored in the columns as well.

[0027] The channels are tubular members that resist vertical compression. In the preferred embodiment discussed and illustrated, the effectiveness of the channels as reinforcement is enhanced because the shape and structure of the columnar channel corresponds to the shape and structure of corners of the cartons. In this instance, a generally rectangular shape. The corners are the regions of greatest compressive strength for the cartons. Each channel adds a ply of material at each corner as well as provides a separate supporting structure in and of itself. Further adding to the channels' efficiency is the fact that the portions of the insert that accommodate the product configuration are strategically located and formed as cut-out, or notched, portions so as not to diminish the stacking strength of the channels. That is, the primary load-bearing portions of the channels are left intact. The channels are secured in placed in large part due to the central panel. The central panel serves a dual purpose of reinforcing the wall between adjoined channels and, in the instance where a handhold is used, reinforces the handhold region.

[0028] Because the insert is collapsible into a substantially flat condition, it is easy to store in quantities ready for use in an instant with minimal effort. Similarly, the insert is easily constructed from a one-piece blank by means of two simple folds and application of an adhesive. This construction can be easily accomplished manually or by machine.

[0029] It can now be appreciated that an insert formed from a single-piece blank is easily set up for use. The insert strategically reinforces the carton handhold and improves stacking strength. Strategically located notches allow the lawn mower deck to fit snugly without danger of scuffing. The insert optimally accommodates the protruding lawn mower handle. The insert also accommodates complementary articles.

[0030] While the invention has been described with particular reference to the preferred embodiments, it is evident that certain aspects of the invention are not limited to the particular details of the examples illustrated, and it is therefore contemplated that other modifications and applications will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications as do not depart from the true spirit and scope of the invention. 

What is claimed is:
 1. An insert for a carton for a product having a collapsible member extending from a base of the product, the insert comprising: a central panel having opposing end regions and a columnar channel member formed at each said end region, said channel members collapsible to a condition substantially coplanar with said central panel.
 2. The invention of claim 1, said channel members defining slotted regions for receiving and substantially immobilizing the base and the collapsed member extending from the base.
 3. The invention of claim 2, wherein the collapsed member is segmented and creates a substantially Z-shaped configuration with said base and said slotted regions are adapted for receiving said Z-shaped configuration.
 4. The invention of claim 3, wherein at least one of the segments of the collapsed member is U-shaped and said slotted regions are adapted for receiving said U-shaped member.
 5. The invention of claim 1, said central panel defining a handhold aperture for alignment with a handhold aperture of the carton and wherein a region adjacent said handhold aperture is reinforced.
 6. An insert for a carton for a product having a U-shaped, segmented collapsible member extending from a base of the product forming a Z-shaped configuration therewith, the insert comprising: a central panel having tubular members formed at end regions thereof, said tubular members defining notched regions adapted for receiving the base and the member of said product and wherein each said tubular member is collapsible into flat-face condition substantially coplanar with said central panel.
 7. The invention of claim 6, wherein each said column is formed by an extension from said central panel terminating in an end portion that is affixed to said central panel.
 8. The invention of claim 7, wherein said central panel defines a handhold aperture disposed for alignment with a second handhold aperture of said carton and wherein said end portion is affixed to said central panel so as to at least partially overlap a circumference of said handhold aperture at a notched region of said end portion thereby reinforcing a region of said handhold aperture.
 9. The invention of claim 7, said extension comprising a plurality of adjoining column panel members.
 10. An insert for a carton for a product having a collapsible member extending from a base of the product of the product, the insert comprising: a pair of columnar channel members collapsible into substantially flat-face contacting relationship adapted for being closely received at a pair of opposing corners of the carton interconnected by a central panel, said columnar channel members having a height substantially equal to a height of said carton so as to reinforce vertical stacking strength of the carton and defining slotted regions for receiving and substantially immobilizing the base and the collapsible member of the product. 